Inflatable packaging cushion with suspension hammock

ABSTRACT

The present invention is directed to an inflatable packaging cushion that may include a plurality of inflation tubes to define a structure of the inflatable packaging cushion, in which the structure includes an interior region defined by the plurality of inflation tubes. The inflatable packaging cushion may further include a suspension hammock positioned within the interior region defined by the plurality of inflation tubes, and connected to at least one of the inflation tubes. The inflatable packaging further also includes a package receiving portion that is configured and dimensioned to receive a product and a suspension portion that is configured to retain and cushion the product within the inflation tubes and suspension hammock. The suspension hammock is configured so that the product within the suspension portion does not extend past an end of the inflatable packaging cushion thereby reducing the likelihood of damage to the product.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Appl. No.62/157,641 filed May 6, 2015, which is hereby incorporated by referencein its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an inflatable packagingcushion with a suspension hammock for receiving a product, and moreparticularly the inflatable packaging cushion with the suspensionhammock and product may be received in a carton, and the inflatablepackaging cushion with the suspension hammock is configured forsuspending and cushioning the product therein.

2. Description of Related Art

Inflatable packaging cushions for cushioning products in cartons areknown in the art as a substitute for foam pellets, air pillows, fittedand unfitted foam blocks and corrugated support structures. All of thesetypes of packaging products are designed to provide cushioning to reduceand/or eliminate the energy that is applied to and/or exerted uponobjects contained within the packaging products during shipping and/ortransport of the objects in order to reduce or avoid damage to suchobjects. Such energy may be the result of forces applied to and/orexerted upon the objects as a result of compression, torsion, flexing orimpact of the cartons containing the objects.

Foam pellets are placed in cartons surrounding a product to fill voidsand separate the product from the walls of the carton and to cushion theproduct. Foam pellets have disadvantages in that they take a substantialamount of shipping and storage space to make them available at the pointof use, and are labor intensive to achieve proper placement andcushioning of the product within its carton. They are also difficult todispose of after use, and are difficult to recycle. They requiresubstantial amount of raw materials and cost to fabricate and transport.

Individual, small air pillows are often used in place of foam pellets tofill voids in cartons, but are also difficult to place operatively forfull protection, and are generally not used for products that require ahigh level of protection and reliability in their packaging.

Foam blocks that are shaped to accommodate a product and to fit snugglyin cartons while supporting the product are also popular. However, theysuffer many of the same disadvantages as foam pellets, in that they areexpensive to fabricate, occupy substantial amount of space in shippingto the point of use and in inventory prior to use, and are relativelylabor intensive to place on a product. They are also bulky and difficultto dispose of, both at the point of unpacking and in recycling.

Corrugated support structures have also been used to support a productwithin a carton, but are relatively expensive, and are also laborintensive to install on the product and fit into a carton, and may notprovide an appropriate level of cushioning or vibration protection. Whencombined with thermoplastic suspension panels, they are not easilyrecycled.

There have been many custom inflatable packaging cushions designed andused with particular products. While custom inflatable packagingcushions may provide good protection for the product, they generallyoccupy a substantial volume which requires the use of large cartons andresults in higher shipping costs, and often designed for a product orproduct box of a specific size, which limits their general usefulness.

Accordingly, there is a need for improved packaging cushions.

SUMMARY OF THE INVENTION

The present invention is designed to overcome the above notedlimitations that are attendant upon the use of conventional packagingmaterials and, toward this end, it contemplates the provision of a novelinflatable packaging cushion having a suspension hammock integratedtherein.

It is a principal object of the invention herein to provide aninflatable packaging cushion for protecting products.

It is a further object of the invention herein to provide an inflatablepackaging cushion for protecting products that may be contained withincartons.

It is still another object of the invention herein to provide aninflatable packaging cushion for reducing and/or eliminatingcompression, torsional, flexing or impact forces exerted upon productscontained within cartons during transport or shipping of the products.

It is yet another object of the invention herein to provide aninflatable packaging cushion for protecting products that may beirregularly shaped and/or have extensions extending therefrom.

It is a further object of the invention herein to provide an inflatablepackaging cushion for protecting asymmetrical products.

It is yet another object of the invention to provide an inflatablepackaging cushion that is adapted for cushioning and/or protectingmultiple types of products.

It is still another object of the invention herein to provide aninflatable packaging cushion that can be used to surround all sides of aproduct and to prevent flexing of the product when surrounded by theinflatable packaging cushion or cushions.

It is a further object of the invention herein to provide an inflatablepackaging cushion that can be readily manufactured.

It is still another object of the invention herein to provide aninflatable packaging cushion is comprised of materials that are suitablefor recycling and/or reuse.

It is an additional object of the invention herein to provide aninflatable packaging cushion for protecting products in cartons thatminimizes the required volume of the carton.

It is a further object of the invention herein to provide an inflatablepackaging cushion for protecting products in cartons that is adaptableto a plurality of products.

It is also an object of the invention herein to provide an inflatablepackaging cushion for protecting products in cartons wherein theinflatable packaging cushion is adapted for easy loading and unloadingof the product.

It is another object of the invention herein to provide a combination ofan inflatable packaging cushion for protecting products in cartons and acarton for receiving the inflatable packaging cushion and product.

It is yet another object of the invention herein to provide aninflatable packaging cushion having a suspension hammock therein that isadapted to protect the inflatable packaging cushion from puncture orother damage from a product contained within the inflatable packagingcushion during shipping or transport of the product.

It is still another object of the invention herein to provide aninflatable packaging cushion that is adjustably inflatable, and can beadapted to have a varying range of density according to the use orapplication for the inflatable packaging cushion.

In carrying out the invention herein, an inflatable packaging cushion isprovided that may include a plurality of inflation tubes to define astructure of the inflatable packaging cushion, in which the structureincludes an interior region defined by the plurality of inflation tubes.The inflatable packaging cushion may further include a suspensionhammock positioned within the interior region defined by the pluralityof inflation tubes, and connected to at least one of the inflationtubes. The inflatable packaging further also includes a packagereceiving portion that is configured and dimensioned to receive aproduct and a suspension portion that is configured to retain andcushion the product within the inflation tubes and suspension hammock.The suspension hammock is configured so that the product within thesuspension portion does not extend past an end of the inflatablepackaging cushion thereby reducing the likelihood of damage to theproduct.

In accordance with an exemplary embodiment of the present invention, theinflatable packaging cushion may include a product housing formed by aplurality of connected inflation tubes defining an interior region ofthe product housing, and a suspension hammock secured to the producthousing and positioned at least partially within the interior region ofthe product housing

In accordance with the exemplary embodiment of the present invention,the product housing of the inflatable packaging cushion may include afirst portion and a second portion. The first portion may be configuredfor receipt of a product, and the second portion may be configured forextension of the suspension hammock to cradle the product, but it isunderstood that the second portion may also be configured for receipt ofthe product and the first portion may be configured for extension of thesuspension hammock to cradle the product.

In accordance with the exemplary embodiment of the present invention, alength of the suspension hammock between a junction between the firstportion and the second portion and a point on the suspension hammockfurthest away from the first portion is less than the length of thesecond portion.

In accordance with the exemplary embodiment of the present invention,the product housing may include a first pair of walls formed from theplurality of connected inflation tubes and positioned parallel withrespect to each other, a second pair of walls formed from the pluralityof connected inflation tubes and positioned parallel with respect toeach other and at an angle with respect to the first pair of walls, andan end wall formed from the plurality of connected inflation tubes andpositioned perpendicular to the first pair of walls and the second pairof walls.

In accordance with the exemplary embodiment of the present invention,the product housing may also include a first end and a second end. Thefirst end may be positioned at an end of the first portion and thesecond end may be positioned at an end of the second portion, and thesuspension hammock may be configured to create a barrier within theinterior region of the product housing between the first end and thesecond end of the product housing.

In accordance with the exemplary embodiment of the present invention,the suspension hammock may be made from a suspension sheet material.

In accordance with the exemplary embodiment of the present invention,the suspension sheet material may be made of a laminate material havinga first side and a second side, and he first side is configured so as tonot be weldable to itself and the plurality of connected inflationtubes.

In accordance with the exemplary embodiment of the present invention,the suspension sheet material may be polytetrafluoroethylene.

In accordance with the exemplary embodiment of the present invention,the suspension hammock may include one or more extension sleevesextending from the suspension hammock to an area outside of the interiorregion of the product housing.

In accordance with the exemplary embodiment of the present invention,each of the plurality of connected inflation tubes may include alongitudinal axis, and the longitudinal axis of each of the plurality ofconnected inflation tubes may be positioned perpendicular to thejunction between the first portion and the second portion.

In accordance with the exemplary embodiment of the present invention,each of the plurality of connected inflation tubes may include alongitudinal axis, and the longitudinal axis of each of the plurality ofconnected inflation tubes may be positioned parallel to the junctionbetween the first portion and the second portion.

In accordance with the exemplary embodiment of the present invention,the suspension hammock may be secured to the product housing at thejunction between the first portion and the second portion of the producthousing.

In accordance with the exemplary embodiment of the present invention,the junction between the first portion and the second portion may be aseam connecting the suspension hammock to the plurality of connectedinflation tubes.

In accordance with the exemplary embodiment of the present invention,the product housing may be configured for receipt of a product bysuspending the product with the suspension hammock within the interiorregion of the product housing.

In accordance with the exemplary embodiment of the present invention,the product housing may be configured for insertion into a carton andfor cushioning the product from contacting at least one of wall of thecarton.

In accordance with the exemplary embodiment of the present invention,each of the plurality of connected inflation tubes is inflatable throughan individual inflation valve.

In accordance with the exemplary embodiment of the present invention,each of the plurality of connected inflation tubes is inflatable throughan individual inflation valve.

In accordance with the exemplary embodiment of the present invention,the plurality of connected inflation tubes are inflatable through aplenum.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a fuller understanding of the nature and object of the presentinvention, reference should be had to the following detailed descriptiontaken in connection with the accompanying drawings, in which:

FIG. 1 is an isometric view of an exemplary inflatable multi-chambercushion that may be used for the inflatable packaging cushion accordingto the present invention, a cutaway is used to show that inflatablemulti-chamber cushion may contain two layers of film;

FIG. 2 is an isometric view of an exemplary suspension sheet that may beused for the inflatable packaging cushion according to the presentinvention, a folded over portion of the suspension sheet indicates thatit may have different types of surfaces/treatments/materials on eachside of the suspension sheet;

FIG. 3 is an isometric view showing the overlay of the suspension sheetfrom FIG. 2 on the inflatable multi-chamber cushion from FIG. 1;

FIG. 4 is an isometric view of the overlay from FIG. 3 folded over onitself;

FIG. 4A is a cross-sectional view taken along line 4A-4A from FIG. 4;

FIG. 5 is an isometric view showing tack welding of the suspension sheetonto the inflatable multi-chamber cushion;

FIG. 5A is a cross-sectional view taken along line 5A-5A from FIG. 5;

FIG. 6A is a bottom isometric view of an exemplary embodiment of aninflatable packaging cushion according to the present invention;

FIG. 6B is a top isometric view of the exemplary embodiment of theinflatable packaging cushion according to the present invention;

FIG. 6C is a cross-sectional view of the exemplary embodiment of theinflatable packaging cushion taken along line 6C-6C in FIG. 6A;

FIG. 7A is a side isometric view of the exemplary embodiment of theinflatable packaging cushion according to the present invention;

FIG. 7B is a side isometric view of the exemplary embodiment of theinflatable packaging cushion according to the present inventioncontaining an exemplary product;

FIG. 8 is a top isometric view of two exemplary inflatable packagingcushions according to the present invention containing the exemplaryproduct;

FIG. 9 is a side view of the two exemplary inflatable packaging cushionsaccording to the present invention containing the exemplary product, inwhich the inflatable packaging cushions are shown transparently in orderto show the exemplary product contained therein;

FIG. 10 is an isometric view of another exemplary inflatablemulti-chamber cushion that may be used for the inflatable packagingcushion according to the present invention;

FIG. 11 is an isometric view of the other exemplary inflatablemulti-chamber cushion folded in half;

FIG. 12 is an isometric view of the other exemplary embodiment of theinflatable packaging cushion with its suspension hammock extendingoutwardly;

FIG. 13 is an isometric view of the other exemplary embodiment of theinflatable packaging cushion with its suspension hammock extendinginwardly;

FIG. 14 is a side isometric view of the other exemplary embodiment ofthe inflatable packaging cushion containing an exemplary product;

FIG. 15 is a bottom isometric view of the other exemplary embodiment ofthe inflatable packaging cushion containing the exemplary product;

FIG. 16 is a bottom isometric view of another exemplary inflatablemulti-chamber cushion that may be used for the inflatable packagingcushion according to the present invention;

FIG. 17 is bottom isometric view of another exemplary inflatablemulti-chamber cushion that may be used for the inflatable packagingcushion according to the present invention;

FIG. 18 is a top isometric view of the other exemplary inflatablemulti-chamber cushion from FIG. 17;

FIG. 19 is bottom isometric view of another exemplary inflatablemulti-chamber cushion that may be used for the inflatable packagingcushion according to the present invention;

FIG. 20 is a top isometric view of the other exemplary inflatablemulti-chamber cushion from FIG. 19;

FIG. 21 is a front isometric view of the other exemplary inflatablemulti-chamber cushion from FIG. 19;

FIG. 22 is a front isometric view of the other exemplary inflatablemulti-chamber cushion from FIG. 19 along with an exemplary productinserted into the inflatable multi-chamber cushion; and

FIG. 23 is a front isometric view of the other exemplary inflatablemulti-chamber cushion from FIG. 19 in which the exemplary product isheld in place by a self-taping extended sleeve.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying figures, in which exemplary embodiments ofthe invention are shown. The invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein. Like reference numerals refer to likeelements throughout.

Referring now to FIGS. 6A, 6B, 6C, 7A and 7B, therein illustrated is anexemplary inflatable packaging cushion, generally indicated by referencenumeral 10, according to the present invention. The inflatable packagingcushion 10 includes a plurality of inflatable tubes 12, and may be madefrom an inflatable multi-chamber cushion that has a plurality of alignedindividual inflatable tubes 12, with each inflatable tube 12 having aself-sealing inflation check valve (not shown) at one end. A manifold(not shown) extends across the ends of the inflatable tubes 12 incommunication with the inflation check valve, and the manifold has anopening at one end thereof for receiving an inflation device. Suitableinflatable multi-chamber cushions that may be used for the inflatablepackaging cushion 10 are described in U.S. Pat. Nos. 7,695,786,7,854,243 and 8,770,408, which are all hereby incorporated by referencein their entireties. The inflatable packaging cushion 10 also includes asuspension hammock 14 affixed to at least some of the inflation tubes 12and configured to extend towards, but not past, an end of the inflatablepackaging cushion 10. The inflatable packaging cushion 10 may be dividedinto a product receiving portion 16 and a suspension portion 18 by aseam 20 that connects the suspension hammock 14 to at least one of theinflation tubes 12. The attachment of the suspension hammock 14 to theinflation tubes 12 will be discussed below with respect to theconstruction of the inflatable packaging cushion 10.

Still referring to FIGS. 6A, 6B, 6C, 7A and 7B, the inflatable packagingcushion 10 is dimensioned and configured to receive a product 25 in theproduct receiving portion 16 such that the product 25 may be extendedinto the suspension portion 18, but the suspension hammock 14 cradlesthe product 25 so that the product 25 does not extend past the end ofthe suspension portion 18. The suspension hammock 14 is adapted tosupport the product 25, and may preferably be constructed of resilientmaterial to provide cushioning for the product 25 by acting as asuspension system within the inflatable packaging cushion 10. Thesuspension hammock 14 may also preferably be adapted to reduce and/oreliminate torsional forces that the product 25 may be subjected toduring transport or shipping of the product 25. Since the suspensionhammock 14 is adapted to function as a suspension system within theinflatable packaging cushion 10, twisting and/or turning motion of acarton containing the product 25 may not be transferred to the product25, since the suspension hammock 14 may act to insulate the product 25from movements of the carton. In this manner, the suspension hammock 14also acts as a protection barrier to puncture and/or damage to theinflatable packaging cushion 10 by the product 25 received within theinflatable packaging cushion 10. It is understood that the presentinvention is not limited to any particular dimension and/orconfiguration, and a rectangular configuration of the inflatablepackaging cushion 10 is illustrated merely for exemplary purposes.However, it is contemplated that the inflatable packaging cushion 10 mayhave any dimension and/or configuration as appropriate for receiving andcushioning any type of product 25, regardless of the shape and/orconfiguration of the product 25. For example, since a plurality ofinflation tubes 12 are utilized and the inflatable packaging cushion 10is bendable at each longitudinal connection between the inflation tubes12, the inflatable packaging cushion 10 may have any shape and/orconfiguration. Exemplary shapes and/or configurations include square,rounded, octagonal, elliptical, diamond, hexagonal and/or pentagonal.While a rectangular shaped product 25 is shown, the present invention isnot limited to the inflatable packaging cushion 10 having the same shapeor configuration as the product 25, in order to function to cushion theproduct 25 during transport or shipping of the product 25. Instead, itis understood that the exemplary rectangular configuration of theinflatable packaging cushion 10 shown FIGS. 6A, 6B, 6C, 7A and 7B mayalso be used for asymmetrically shaped products (not shown). In thismanner, the same inflatable packaging cushion 10 configuration isadapted for multi-purpose use as a result of being adapted to receiveand cushion multiple different products and/or product configurations.

Still referring to FIGS. 6A, 6B, 6C, 7A and 7B, the connection of thesuspension hammock 14 to the inflation tubes 12 creates the seam 20 thatdivides the inflatable packaging cushion 10 into the product receivingportion 16 and the suspension portion 18. It is preferable that thesuspension hammock 14 is connected to one or more inflation tubes 12such that the product 25 can be sufficiently cradled by the suspensionhammock 14 so that it is not possible that the product 25 can slip pastthe suspension hammock 14 and extend out of the suspension portion 18 ofthe inflatable packaging cushion 10. For example, the suspension hammock14 may be connected to inflation tubes 12 on opposite sides of theparticular configuration of the inflatable packaging cushion 10. It isalso preferable that the suspension hammock 14 be dimensioned andattached to the inflation tubes 12 such that the suspension hammock 14does not extend past the end of the suspension portion 18 so that noportion of the product extends outside of the inflatable packagingcushion 10. It may be even more preferable that the suspension hammock14 is positioned a sufficient distance away from the end of thesuspension portion 18 so that normal compression of the inflation tubes12 does not result in the product 25 contained within the suspensionhammock 14 extending outside of the inflatable packaging cushion 10,which thereby may result in damage to the product 25.

Referring now to FIGS. 7B, 8 and 9, the use of the inflatable packagingcushion 10 according to the present invention to contain and cushion theproduct will now be discussed. As shown in FIG. 7B, the product 25 maybe inserted into product receiving portion 16 and extended into thesuspension portion 18. As discussed above, the suspension hammock 14cradles the product 25 and prevents the product 25 from extending pastthe end of the suspension portion 18 and out of the inflatable packagingcushion 10. A second inflatable packaging cushion 10 may now be placedon the other end of the product 25 such that the product issubstantially completely enclosed by the inflatable packaging cushions10 as shown for example in FIGS. 8 and 9. With the two inflatablepackaging cushions 10 installed on the product 25, the product 25 is nowcushioned from potential damage on all sides of the product 25 as aresult of the inflation tubes 12 acting as cushioning on the top, bottomand sides of the product 25, and the suspension hammocks 14 incombination with the ends of the inflation tubes 12 extending past thesuspension hammocks 14 in the suspension portion 18 cradling andcushioning the ends of the product 25. The product 25 is alsosubstantially enclosed within the inflatable packaging cushions 10 suchthat flexing of the product 25 is unlikely to occur due to theuniformity of cushioning containing the product 25. While the product 25is shown having a substantially regular shape, it is understood that theinflatable packaging cushion 10 according to the present invention issuitable for use of any shaped product, whether regular or irregular,for example as a result of components of the product extendingirregularly from the product such that normal packaging systems wouldnot be suitable for cushioning the irregularly shaped product. It isfurther understood that while the inflation tubes 12 of the exemplaryinflatable packaging cushion 10 are shown running vertically andperpendicular to the seam 20, it is contemplated that the inflationtubes 12 may also run horizontally and parallel with the seam 20.

Referring now to FIGS. 1-4, 4A, 5 and 5A, the construction of anexemplary inflatable packaging cushion 10 according to the presentinvention will be discussed. FIG. 1 shows standard inflatablemulti-chamber cushion in its deflated configuration, in which a gas hasnot yet been introduced into the inflation tubes 12. The multi-chambercushion maybe constructed from two layers of suitable film and containsvalves 30 configured for introduction of air or other gases into theinflation tubes 12. FIG. 2 shows a suspension sheet 32 that isconfigured for single side welding, and may be used to construct thesuspension hammock 14 of the inflatable packaging cushion 10 accordingto the present invention. The suspension sheet 32 may preferably be madefrom a resilient material that is adapted to stretch, but still returnto substantially its original position. The suspension sheet 32 includesa first side 34 and a second side 36, and may be constructed so that thesecond side 36 is configured for welding to the inflation tubes 12, butthe first side 34 is configured so that it does not weld to itself. Thiscan be accomplished by having a coextruded and/or laminated material, inwhich a material of the second side 36 is capable of being welded toitself and/or the material of the inflation tubes, but a material usedfor the first side 34 does not weld to itself. Furthermore, printing maybe used on the first side 34 so that the printing interferes and/orprevents welding the first side 34 to itself. As another alternative, amaterial such as polytetrafluoroethylene (PTFE) can be used that can bewelded to the material of the inflation tubes 12, but not to itself. Asshown in FIG. 3, the suspension sheet 32 is laid over a portion of theinflation tubes 12, such that the first side 34, or the side that doesnot weld to itself, is facing away from the inflation tubes 12.

As shown by the arrow in FIG. 3, the combination of the suspension sheet32 and inflation tubes 12 are then folded over upon themselves toproduce the configuration shown in FIGS. 4 and 4A. In thisconfiguration, the first side 34 of the suspension sheet 32 ispositioned between the second side 36 of the suspension sheet 32, andthe second side 36 of the suspension sheet 32 is in contact with theinflation tubes 12. As shown in FIGS. 5 and 5A, then suspension sheet 32may then be welded to at least one of the inflation tubes 12 by one ormore welds 38, and preferably the inflation tubes 12 are in two layersso welding at one inflation tube 12 location also welds the suspensionsheet 32 to the corresponding inflation tube 12. The welding of thesuspension sheet 32 to the inflation tubes 12 creates the suspensionhammock 14 of the inflatable packaging cushion 10, which is shown in acollapsed deflated configuration in FIGS. 5 and 5A, and attached to theinflated packaging cushion 10 at the welds 38. The inflatable packagingcushion 10 may then be inflated by introducing suitable gas and/or airinto the inflation tubes 12, and then the ends of the inflated packagingcushion 10 may be connected together by welding and/or suitableadhesives to form the desired configuration for the product on which theinflated packaging cushion 10 will be used. For example, the inflatedpackaging cushion 10 shown in FIGS. 6A and 6B has a substantiallyrectangular configuration in order to receive and cushion rectangularpackage 25. The inflation tubes 12 of the inflatable packaging cushion10 are configured to be adjustably inflatable, and preferably may beinflated to a variety of internal pressures, for example 10 to 20 psi,depending upon the application or use of the inflatable packagingcushion 10. The adaptability of the inflation pressure of the inflationtubes 12 allows for the inflatable packaging cushion 10 to have varyingdensity due to the amount of gas and/or air introduced into theinflation tubes 12. The density of the inflatable packaging cushion 10can be used to adjust cushioning provided by the inflatable packagingcushion 10. However, it understood that the present invention is notlimited to any inflation pressure of the inflation tubes 12 or anyparticular density of the inflatable packaging cushion 10. It is alsounderstood that the density of the inflation tubes 12 refers to therelative firmness or softness of the inflation tubes 12 and is notnecessarily limited to the mass per unit volume of the inflation tubes12.

In addition to adjusting the density of the inflation tubes 12 byinflating the inflation tubes 12 to a variety of internal pressures, thedensity of the inflation tubes 12 may also be adjusted by allowing forcontrolled displacement of the gas and/or air present in the inflationtubes 12. The displacement of gas and/or air within the inflation tubes12 as the result of an external force applied to the inflation tubes 12,for example motion of a product within the inflatable packaging cushion10, can be adjusted by a number of factors. For example, the diameter ofthe inflation tubes 12 used for the inflatable packaging cushion 10 canbe increased or decreased in order to allow for greater or lesserdensity of the inflation tubes 12 at the same inflation pressure. Ingeneral, larger diameter inflation tubes 12 tend to react slower toexternal forces, thereby giving such inflation tubes 12 a greaterrelative density, while smaller diameter inflation tubes 12 react fasterto external forces.

The reaction of the inflation tubes 12 to external forces is influencedby the amount of gas and/or air displaced within the inflation tubes 12as a result of the external force. Larger diameter inflation tubes 12tend to have greater relative densities compared to smaller diameterinflation tubes 12, because if the same external force is applied toboth sizes of inflation tubes 12, the relative displacement of gasand/or air in the smaller diameter inflation tubes 12 will be greater,thereby providing softer cushioning and lower relative density.

By the same token, the displacement of the gas and/or air within theinflation tubes 12 may be controlled by changing the length of theinflation tubes 12 through the use of hinges and/orcompartmentalization. For example, different sections of the inflatablepacking cushion 10 may have different densities of inflation tubes 12due to the length of the inflation tubes 12 in the various sections. Forexample, a section of the inflatable packaging cushion 10 with shortinflation tubes 12 may have a relatively low density, thereby providinga softer cushioning effect, due to the lesser amount of gas and/or airwithin the short inflation tubes 12. However, a section of theinflatable packing cushion 10 with long inflation tube 12 lengths mayhave a relatively high density, thereby providing a firmer cushioningeffect, due to the greater amount of gas and/or air within the longinflation tubes 12. Therefore, it is understood that the while thepresent invention is not limited to any particular relative density ofthe inflation tubes 12 that may be used for embodiments of theinflatable packaging cushion 10, the present invention does providemeans for controlling the density of the inflation tubes 12 throughmechanisms that affect the displacement activity occurring within theinflation tubes 12 due to external forces exerted upon the inflationtubes 12.

Referring now to FIGS. 12-15, therein illustrated is another exemplaryinflatable packaging cushion, generally indicated by reference numeral110, according to the present invention. The inflatable packagingcushion 110 includes a plurality of inflatable tubes 112, and may bemade from an inflatable multi-chamber cushion that has a plurality ofaligned individual inflatable tubes 112, with each inflatable tube 112having a self-sealing inflation check valve (not shown) at one end. Amanifold (not shown) extends across the ends of the inflatable tubes 112in communication with the inflation check valve, and the manifold has anopening at one end thereof for receiving an inflation device. Suitableinflatable multi-chamber cushions that may be used for the inflatablepackaging cushion 110 are described in U.S. Pat. Nos. 7,695,786,7,854,243 and 8,770,408, which, to any extent not already done so, areall hereby incorporated by reference in their entireties. The inflatablepackaging cushion 110 also includes a suspension hammock 114 affixed toat least some of the inflation tubes 112 and configured to extendtowards, but not past, an end of the inflatable packaging cushion 110.The inflatable packaging cushion 110 may be divided into a productreceiving portion 116 and a suspension portion 118, and it is understoodthat the suspension hammock 114 may be positioned to extend past the endof the product receiving portion 116, as shown for example in FIG. 12,but does not extent past the suspension portion 118, as show for examplein FIG. 15. The attachment of the suspension hammock 114 to theinflation tubes 112 will be discussed below with respect to theconstruction of the inflatable packaging cushion 110.

Still referring to 12-15, the inflatable packaging cushion 110 isdimensioned and configured to receive a product 125 in the productreceiving portion 116 such that the product 125 may be extended into thesuspension portion 118, but the suspension hammock 114 cradles theproduct 125 so that the product does not extend past the end of thesuspension portion 118. It is understood that the present invention isnot limited to any particular dimension and/or configuration, and arectangular configuration of the inflatable packaging cushion 110 isillustrated merely for exemplary purposes. However, it is contemplatedthat the inflatable packaging cushion 110 may have any dimension and/orconfiguration as appropriate for receiving and cushioning any type ofproduct 125, regardless of the shape and/or configuration of theproduct. For example, since the inflatable packaging cushion 110 isbendable at each seam 126 formed in the inflation tubes 112, theinflatable packaging cushion 110 may have any shape and/orconfiguration. Exemplary shapes and/or configurations include square,rounded, octagonal, elliptical, diamond, hexagonal and/or pentagonal.The suspension hammock 114 may be connected to the inflation tubes 112at any suitable location, and preferably on a seam between two of theinflation tubes 112. It is preferable that the suspension hammock 114 isconnected to the inflation tubes 112 such that the product 125 can besufficiently cradled by the suspension hammock 114 so that it is notpossible that the product 125 can slip past the suspension hammock 114and extend out of the suspension portion 118 of the inflatable packagingcushion 110. It is also preferable that the suspension hammock 114 bedimensioned and attached to the inflation tubes 112 such that thesuspension hammock 114 does not extend past the end of the suspensionportion 118 so that no portion of the product extends outside of theinflatable packaging cushion 110. It may be even more preferable thatthe suspension hammock 114 is positioned a sufficient distance away fromthe end of the suspension portion 118 so that normal compression of theinflation tubes 112 does not result in the product 125 contained withinthe suspension hammock 114 extending outside of the inflatable packagingcushion 110, which thereby may result in damage to the product 125.

Referring now to FIGS. 14 and 15, the use of the inflatable packagingcushion 110 according to the present invention to contain and cushionthe product will now be discussed. As shown in FIGS. 14 and 15, theproduct 125 may be inserted into product receiving portion 116 andextended towards the suspension portion 118. As discussed above, thesuspension hammock 114 cradles the product 125 and prevents the product125 from extending past the end of the suspension portion 118 and out ofthe inflatable packaging cushion 110. A second inflatable packagingcushion (not shown) may be placed on the other end of the product 125such that the product is substantially completely enclosed by theinflatable packaging cushions 110. With two inflatable packagingcushions 110 installed on the product 125, the product 125 is nowcushioned from potential damage on all sides of the product 125 as aresult of the inflation tubes 112 acting as cushioning on the top,bottom and sides of the product 125, and the suspension hammocks 114 incombination with the inflation tubes 112 extending past the suspensionhammocks 114 in the suspension portion 118 cradling and cushioning theends of the product 125. The product 125 is also substantially enclosedwithin the inflatable packaging cushions 110 such that flexing of theproduct 125 is unlikely to occur due to the uniformity of cushioningcontaining the product 125. While the product 125 is shown having asubstantially regular shape, it is understood that the inflatablepackaging cushion 110 according to the present invention is suitable foruse of any shaped product, whether regular or irregular, for example asa result of components of the product extending irregularly from theproduct such that normal packaging systems would not be suitable forcushioning the irregularly shaped product.

Referring now to FIGS. 10-13, the construction of an exemplaryinflatable packaging cushion 110 according to the present invention willbe discussed. FIG. 10 shows a standard inflatable multi-chamber cushionin which a gas has been introduced into some of the inflation tubes 112,and the remainder of the inflation tubes 112 are left in a deflatedstatus in order to provide a sheet of material that can be used for thesuspension hammock 114, as discussed further below. One or more seams126 may be formed or provided in each inflation tube 112 in order toallow for folding and/or bending of the multi-chamber cushion, as shownfor example in FIG. 11. The multi-chamber cushion may then be welded orglued with suitable adhesive along the top and left-side edge as shownin FIG. 11 in order to permit the inflatable packaging cushion 110 to beopened into the configuration shown in FIG. 12. Once in theconfiguration shown in FIG. 12, the suspension hammock 114 is thenpushed in towards the interior region of the inflatable packagingcushion 110 in order to position the suspension hammock 114 within theinflatable packaging cushion 110, as shown in FIG. 13. In theconfiguration shown in FIG. 13, the inflatable packaging cushion 110 isnow configured to receive and support a package or other object.

FIGS. 16-23 show alternative embodiments and/or modifications of theinflatable packaging cushion according to the present invention. Forexample, FIG. 16 shows an exemplary embodiment of an inflatablepackaging cushion 210 that is substantially similar to the inflatablepackaging cushion 10 discussed above, and like elements are identifiedby reference numerals increased by 200. The inflatable packaging cushion210 shown in FIG. 16 provides an exemplary of an alternative shape andconfiguration for the inflatable packaging cushion 210, and that thesuspension hammock 214 may be welded to the one or more inflation tubes212 at an end of the inflatable packaging cushion 210 instead of in theinterior of the inflatable packaging cushion 210. By welding thesuspension hammock 214 to the one or more inflation tubes 212 at the endof the inflatable packaging cushion 210 it may provide the benefit offacilitating manufacture of the inflatable packaging cushion 210. Theprovisional of an alternative embodiment of inflatable packaging cushion210 does not in any way preclude the previously discussed embodiments ofthe inflatable packaging cushion according to the present invention fromhaving the features specifically shown in FIG. 16.

Referring now to FIGS. 17-18, therein illustrated is another exemplaryembodiment of an inflatable packaging cushion 310 according to thepresent invention. The inflatable packaging cushion 310 is substantiallysimilar to the inflatable packaging cushion 10 discussed above, and likeelements are identified by reference numerals increased by 300. Theinflatable packaging cushion 310 provides an example as to how theinflation tubes 312 may be extended around an end of the inflatablepackaging cushion 310 so as to provide additional cushioning for fragileproducts that may be inserted into the inflatable packaging cushion 310.In contrast to inflatable packaging cushion 10, which in no way isprecluded from having any or all of the features of inflatable packagingcushion 310, in which the ends are open, inflatable packaging cushion310 has a closed top design in which the inflation tubes 312 extendaround an end of the suspension hammock 314.

Referring now to FIGS. 19-23, therein illustrated is another exemplaryembodiment of an inflatable packaging cushion 410 according to thepresent invention. The inflatable packaging cushion 410 is substantiallysimilar to the inflatable packaging cushion 10 discussed above, and likeelements are identified by reference numerals increased by 400. Theinflatable packaging cushion 410 includes extended sleeves of thesuspension hammock 414 that may include a self-taping adhesive in orderto allow for closure of the extended sleeves, as seen for example inFIG. 23. As shown in FIGS. 21-23, the exemplary product 425 may includea portion that is more fragile than the rest of the product 425, so thisportion may be inserted into the inflatable packaging cushion 410, whilethe remainder of the product 425 is held in place with the extendedsleeves of the suspension hammock 414. The suspension hammock 414 isadapted to receive asymmetrical products, such as the exemplary product425, and it is understood that the inflatable packaging cushion 410 isconfigured for use with multiple different product configurations. Inthis manner, it is not necessary to have multiple packaging meansavailable when preparing multiple different types of products forshipping or transport. Instead, the inflatable packaging cushion 410 canbe used for a variety of different products of varying shapes and sizes,and thereby reduces the need to keep inventory of multiple differenttypes of packaging means. It is understood that this advantageous aspectof the present invention is not limited to inflatable packaging cushion410, but applies equally well to the other exemplary embodiments of theinflatable packaging cushions discussed above.

It will thus be seen that the objects set forth above, among those madeapparent from the preceding description, are efficiently attained and,since certain changes may be made in the above article without departingfrom the scope of this invention, it is intended that all mattercontained in this disclosure or shown in the accompanying drawings,shall be interpreted, as illustrative and not in a limiting sense. It isto be understood that all of the present figures, and the accompanyingnarrative discussions of corresponding embodiments, do not purport to becompletely rigorous treatments of the invention under consideration. Itis to be understood that the above-described arrangements are onlyillustrative of the application of the principles of the presentinvention. Numerous modifications and alternative arrangements may bedevised by those skilled in the art without departing from the scope ofthe present invention.

What is claimed is:
 1. An inflatable packaging cushion, comprising: aproduct housing formed by a plurality of connected inflation tubesdefining an interior region of the product housing; and a suspensionhammock secured to the product housing and positioned at least partiallywithin the interior region of the product housing; wherein the producthousing of the inflatable packaging cushion comprises a first portionand a second portion; and wherein a length of the suspension hammockbetween a junction between the first portion and the second portion anda point on the suspension hammock furthest away from the first portionis less than the length of the second portion.
 2. The inflatablepackaging cushion according to claim 1, wherein the product housingcomprises a first pair of walls formed from the plurality of connectedinflation tubes and positioned parallel with respect to each other, asecond pair of walls formed from the plurality of connected inflationtubes and positioned parallel with respect to each other and at an anglewith respect to the first pair of walls, and an end wall formed from theplurality of connected inflation tubes and positioned perpendicular tothe first pair of walls and the second pair of walls.
 3. The inflatablepackaging cushion according to claim 1, wherein the product housingcomprises a first end and a second end, wherein the first end ispositioned at an end of the first portion and the second end ispositioned at an end of the second portion, and wherein the suspensionhammock creates a barrier within the interior region of the producthousing between the first end and the second end of the product housing.4. The inflatable packaging cushion according to claim 1, wherein thesuspension hammock is comprised of a suspension sheet material.
 5. Theinflatable packaging cushion according to claim 4, wherein thesuspension sheet material is comprised of a laminate material having afirst side and a second side, and wherein the first side is configuredso as to not be weldable to itself and the plurality of connectedinflation tubes.
 6. The inflatable packaging cushion according to claim4, wherein the suspension sheet material is polytetrafluoroethylene. 7.The inflatable packaging cushion according to claim 1, wherein thesuspension hammock comprises one or more extension sleeves extendingfrom the suspension hammock to an area outside of the interior region ofthe product housing.
 8. The inflatable packaging cushion according toclaim 1, wherein each of the plurality of connected inflation tubescomprises a longitudinal axis, and wherein the longitudinal axis of eachof the plurality of connected inflation tubes is positionedperpendicular to the junction between the first portion and the secondportion.
 9. The inflatable packaging cushion according to claim 1,wherein each of the plurality of connected inflation tubes comprises alongitudinal axis, and wherein the longitudinal axis of each of theplurality of connected inflation tubes is positioned parallel to thejunction between the first portion and the second portion.
 10. Theinflatable packaging cushion according to claim 1, wherein thesuspension hammock is secured to the product housing at the junctionbetween the first portion and the second portion of the product housing.11. The inflatable packaging cushion according to claim 1, wherein thejunction between the first portion and the second portion is a seamconnecting the suspension hammock to the plurality of connectedinflation tubes.
 12. The inflatable packaging cushion according to claim1, wherein the product housing is configured for receipt of a product bysuspending the product with the suspension hammock within the interiorregion of the product housing.
 13. The inflatable packaging cushionaccording to claim 12, wherein the product housing is configured forinsertion into a carton and for cushioning the product from contactingat least one of wall of the carton.
 14. The inflatable packaging cushionaccording to claim 1, wherein each of the plurality of connectedinflation tubes is inflatable through an individual inflation valve.